Digital fabric devoré (burnout)

ABSTRACT

Provided herein is a composition for digital burnout of a fabric, comprising a fiber-selective burnout agent and a carrier, being formulated for ejection from inkjet machinery. Also provided are a process, a machine and an algorithm for using and deploying the composition for digital burnout of a fabric.

RELATED APPLICATION

This application claims the benefit of priority under 35 USC § 119(e) of U.S. Provisional Patent Application No. 62/437,773 filed on Dec. 22, 2016, the contents of which are incorporated herein by reference in their entirety.

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiments thereof, relates to advanced fabric fashioning and, more particularly, but not exclusively, to digital processes for fabric devoré (burnout) and burnout compositions formulated for direct application by inkjet printing machinery and techniques.

Devoré (hereinafter referred to as “burnout”) is a process whereby a fabric, typically a mixed fiber fabric comprising cellulose fibers, is treated in a predetermined pattern with a chemical agent formulated in a paste. In industrial scale this process is carried by screen printing methodologies using reagents such as aluminum sulfate or sodium hydrogen sulfate that carbonizes the cellulosic fibers in the printed areas. After printing, the treated fabric is then heated to activate the chemical agent and initiate the burning process that destroys the cellulosic fibers in the printed areas of the fabric. The non-printed or non-treated areas remain intact whilst the printed (burnt areas) are washed away leaving behind a fabric which now has open/transparent or sheer areas of fabric in those previously printed or treated areas. Fiber mixes commonly used for this cellulose-burnout process include polyester (synthetic)/cotton (cellulosic), polyester (synthetic)/viscose (cellulosic) and silk (proteinous)/viscose (cellulosic) at a ratio that ranges from 30:70% to 70:30%. A typical paste used in presently known burnout processes typically comprises a synthetic thickener, sodium bisulfate or another acid, a penetrating agent, glycerin and water.

While inkjet technology is becoming more pivotal in high-end textile, fashion and garment production, burnout processes have not been practiced using inkjet methodologies and machinery, particularly since the reagents used for fabric burnout are corrosive and non-injectable for mechanical as well as chemical reasons.

Problems associated with inkjet printing liquid inks directly on absorptive substrates, such as textile and garments, have been mitigated in U.S. Patent Application Publication No. 20150152274, and PCT Application Nos. WO 2005/115089 and WO 2005/115761, by the present assignee, and which are incorporated by reference as if fully set forth herein. These documents teach a process, a composition and an apparatus for printing an image on an absorptive surface, such as an untreated (a substrate that has not been pre-treated chemically) textile piece, that includes applying a wetting composition on the surface which is capable of interfering with the engagement of a liquid ink composition with the binding sites of the surface. According to the processes taught in these patent applications, once the wetting composition is applied, the liquid ink composition is applied while the surface is still wet. Using this process, a vivid color image is formed on the absorptive surface. These patent applications, however, fail to address the limitations associated with printing a color image on an absorptive dark surface.

Multi-part ink compositions, which are based on contacting an immobilizing composition and a colored ink composition on the surface of an untreated substrate, so as to congeal the colored ink composition on the substrate, thereby minimizing feathering and soaking thereof into absorptive substrates, are also taught in U.S. patent application Ser. No. 11/588,277 (U.S. Patent Application Publication No. 20070104899), U.S. patent application Ser. No. 11/606,242 (U.S. Patent Application Publication No. 20070103529), and U.S. Provisional Patent Application No. 62/387,154, all of which are incorporated by reference as if fully set forth herein.

SUMMARY OF THE INVENTION

Aspect so the present invention are drawn to compositions, processes, machine and algorithms for digitally forming a burnout (devoré) pattern on a fabric. Also provided herein are products and articles of manufacturing made by using the compositions, processes, machine and algorithms provided herein.

According to an aspect of some embodiments of the present invention there is provided a composition for digital burnout of a fabric that includes an acid-releasing polymer and a carrier, being formulated for ejection from inkjet machinery.

According to some embodiments of the invention, the composition is formulated for soaking into the fabric to thereby reach a plurality of fibers constituting the fabric.

According to some embodiments of the invention, the dynamic viscosity and/or the Brookfield viscosity at printing temperature and/or the surface tension and/or the electrical resistance of the composition is suitable for inkjet, namely suitable for ejection from an inkjet printhead as this device is known in the art.

According to some embodiments of the invention, the digital burnout composition presented herein is characterized by at least one of:

a maximal particle size of less than 1 microns;

a dynamic viscosity at shear that ranges from 2 to 25 centipoise;

a Brookfield viscosity less than 25 centipoises at printing temperature;

a surface tension that ranges from 24 to 35 mN/m; and

an electrical resistance of 50 to 2000 ohm per centimeter.

According to some embodiments of the invention, the carrier of the burnout composition is deionized water, and the composition further includes at least one additional ingredient selected from the group consisting of a wetting agent (humectant), a thickening agent, a surfactant, an antibacterial agent, a fungicide, an anticorrosion agent and any combination thereof.

According to some embodiments of the invention, the concentration of the acid-releasing polymer ranges from 5% wt to 20% wt.

According to some embodiments of the invention, the acid-releasing polymer comprises an alkyl phosphate group, an alkyl-alkoxy phosphate groups and a combination thereof.

According to some embodiments of the invention, the alkyl in the alkyl phosphate group and/or the alkyl-alkoxy phosphate group is a C8-20 linear alkyl.

According to some embodiments of the invention, the acid-releasing polymer is a polyoxyethylene alkyl ether phosphate.

According to some embodiments of the invention, the acid-releasing polymer is represented by general Formula I:

wherein:

each of Z1 and Z₂ is independently H or a moiety represented by general Formula II:

provided that at least one of Z₁ and Z₂ is the moiety;

A+ is H+ or a metal cation or an ammonium ion;

n is an integer that ranges from 50-200; and

R is a C₈₋₂₀ alkyl.

According to some embodiments of the invention, the acid-releasing polymer is having an average molecular weight which ranges from 3000 g/mol to 10000 g/mol.

According to some embodiments of the invention, the acid-releasing polymer releases phosphoric acid upon heating the composition to 160° C. or higher.

According to some embodiments of the invention, the composition is substantially devoid of phosphoric acid at a temperature that ranges from room temperature to inkjet printhead working temperature (e.g., 20° C. to 40° C.).

According to some embodiments of the invention, the composition has a pH that ranges from 2 to 5 at room temperature.

According to an aspect of some embodiments of the present invention there is provided a process for digital burnout of fabrics, that includes:

providing a fabric; and

digitally printing (e.g., deploying by an inkjet printhead) a digital burnout composition on the fabric in a predetermined digital pattern,

wherein the digital burnout composition comprises an acid-releasing polymer and a carrier, the fabric comprises a cellulosic fiber.

According to some embodiments of the invention, the digital burnout composition is formulated for ejection from inkjet machinery, essentially as described herein.

According to some embodiments of the invention, the fabric comprises a cellulosic fiber and a synthetic and/or proteinous fiber.

According to some embodiments of the invention, the fabric comprises at least 20% cellulosic fiber.

According to some embodiments of the invention, the fabric consists of a cellulosic fiber.

According to some embodiments of the invention, the process further includes, subsequent to printing, heating the fabric to at least 160° C. to thereby degrade the cellulosic fiber.

According to some embodiments of the invention, the process further includes, subsequent to the heating, removing residues of a degraded cellulosic fiber.

According to an aspect of some embodiments of the present invention there is provided a process for digital cutting of a fabric consisting of degradable fibers, the process comprising:

placing the fabric in a inkjet printing machine equipped with at least one inkjet printhead; and

digitally printing a composition for digital burnout of a fabric on at least a part of the fabric, following a predetermined digital pattern.

wherein the composition comprises at least one degradable fiber-specific burnout agent for each degradable fiber in the fabric.

According to some embodiments of the invention, the digital burnout composition is formulated for ejection from inkjet machinery, essentially as described herein.

According to some embodiments of the invention, the process further includes, subsequent to the printing, heating the fabric to at least 160° C. to thereby degrade the degradable fibers.

According to some embodiments of the invention, the process further includes, subsequent to the heating, removing residues of the degraded degradable fibers.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings:

FIG. 1 presents a photograph of the cotton fabric cut using the digital burnout composition and process essentially as described herein.

DESCRIPTION OF SOME SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiments thereof, relates to advanced fabric fashioning and, more particularly, but not exclusively, to digital processes for fabric devoré (burnout) and burnout compositions formulated for direct application by inkjet printing machinery and techniques.

The principles and operation of the present invention may be better understood with reference to the figures and accompanying descriptions.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details set forth in the following description or exemplified by the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

As mentioned hereinabove, currently used inkjet printing technologies are not suitable for fabric burnout, particularly since the reagents are not suitable and/or cannot be formulated for inkjet settings.

While conceiving the present invention, the present inventors have contemplated a composition that will be suitable for inkjet settings, and at the same time will include a compound that can burnout some types of fibers used in the textile industry, such as cellulosic fibers, proteinous fibers or synthetic fibers, whereas some of the fibers will be impervious (resistive; imperishable; tenable) to the burnout effect of the compound. In other words, the compound selectively burns-out (carbonizes) some types of fibers but not burnout other types, thereby a mixed fiber fabric may be etched with a predetermined pattern, which is formed on the fabric digitally, using an inkjet printing machine that applies the composition using a printhead.

While searching for suitable compositions and ingredients, the present inventors have surprisingly found that some types of polymeric surfactants and dispersants, typically used to disperse solids and other insoluble in water, can release a strong acid when heated, and this acid can carbonize cellulosic fibers selectively when applied at a suitable concentration. It was surprisingly found that when used in an aqueous composition, these acid-releasing polymers are harmless to inkjet machinery (printheads, surfaces and environment), and can therefore be applied by printing the composition using an inkjet printhead to form any predetermined digitally designed pattern.

It was also surprisingly found that the reactivity of the acid-releasing polymer can be employed to cut fabrics made of cellulosic fibers. While reducing the present invention to practice, pure cellulosic fiber fabrics were cut along a line that a composition comprising an acid-releasing polymer was printed along using a standard printhead, while a fabric consisting of synthetic fibers was impervious to the composition.

Composition for Digital Burnout of Fabrics:

According to an aspect of embodiments of the present invention, there is provided a composition that is formulated for ejection from inkjet machinery (an inkjet-suitable composition), which includes a fiber-selective burnout agent and a carrier, the fiber-selective burnout agent selectively degrades, corrodes, etches, digests or carbonizes cellulosic or proteinous fibers, collectively referred to herein as degradable fibers. Herein and throughout, the term “degrade” refers to the effect of contacting a cellulosic or proteinous fiber with a cellulosic or proteinous fiber-specific burnout agent upon heating, respectively. A burnout agent which is intended to burnout cellulosic fibers selectively is referred to herein as a cellulosic fiber-selective burnout agent. A burnout agent which is intended to burnout proteinous fibers selectively is referred to herein as a proteinous fiber-selective burnout agent.

The phrase “formulated for ejection from inkjet machinery” and the term “inkjet-suitable”, in the context of a composition that includes a fiber-selective burnout agent, refers to the combined chemical and mechanical properties of the composition and the agent being suitable for inkjet, which include any one or more properties, such as viscosity that is suitable for inkjet application from an inkjet printhead (e.g., 2-25 centipoise), a formulation that will allow direct ejection of composition droplets controllably in terms of drop size, location on the substrate, drop density on the substrate and other controllable parameters, a formulation that will allow the droplets to soak into the fabric to reach the fibers it consists of, a reactivity that is substantially harmless to inkjet machinery parts (non-corrosive and non-volatile) yet reactive upon heating to degrade at least some of the fibers constituting the fabric, and being safe for use in terms of work environment and end-user safety (non-toxic and non-flammable).

In general, for a composition to be inkjet-suitable, it is characterized by at least one of:

a maximal particle size of less than 1 microns;

a dynamic viscosity at shear that ranges from 2 to 25 centipoise;

a Brookfield viscosity less than 25 centipoises at printing temperature;

a surface tension that ranges from 24 to 35 mN/m; and

an electrical resistance of 50 to 2000 ohm per centimeter.

In terms of other ingredient of the composition which are used to render the composition inkjet-suitable, according to some embodiments of the present invention, the carrier is deionized water, and the composition further includes any one or more of a wetting agent (humectant) such as glycerin and/or any glycol ether, a thickening agent (rheology modifier) such as polyvinylpyrrolidone, a surfactant such as Dynol 360 or Byk 348, an antibacterial agent, a fungicide and an anticorrosion agent.

In the context of embodiments of the present invention, the term “fiber-selective burnout agent”, refers to a substance that can controllably degrade at least one type of a fiber used in textile, such as cellulosic fibers or proteinous fibers. Cellulosic fibers include, without limitation, cotton fibers, jute fibers, flax fibers, hemp fibers, ramie fibers, sisal fibers and/or coir fibers, in any combination. Proteinous (animal) fibers include, without limitation, silk fibers, wool fibers and hair fibers.

In some embodiments, at least one type of fiber used in the textile industry is impervious to the fiber-selective burnout agent, such as synthetic fibers. Synthetic fibers that are typically used in the production of fabrics as threads and otherwise, include polyester fibers, polyurethane fibers, polyamide fibers, polyacryl fibers, polyolefin fibers, polybenzimidazole fibers, and any co-polymer thereof, Nylon fibers, polyacrylonitrile (Modacryl) fibers, Rayon fibers, Vinyon fibers, Saran fibers, Spandex fibers, Vinalon fibers, Aramid fibers, Modal® fibers, Dyneema® fibers and Spectra® fibers, and combination thereof.

In some embodiments, the fiber-selective burnout agent is a proteinous-selective burnout agent, namely an agent that degrades proteinous fibers, while cellulosic and synthetic fibers are impervious thereto. Proteinous-selective burnout agents include, without limitation, amide-bond hydrolysis agents and catalysts, proteolytic enzymes and a combination thereof.

In some embodiments, the fiber-selective burnout agent is a cellulosic-selective burnout agent, namely an agent that degrades cellulosic fibers, while proteinous and synthetic fibers are impervious thereto.

In some embodiments of the present invention, the cellulosic-selective burnout agent is an acid-releasing burnout agent, such as an acid-releasing polymer, which is combined with a suitable carrier in a composition for digital burnout of fabrics. This composition is particularly useful for digital burnout of mixed fiber fabrics which include cellulosic fibers, and digital cutting of pure cellulosic fabrics. In the context of some embodiments of the present invention, an acid-releasing polymer is cellulosic-selective burnout agent. In some embodiments, the acid which is release from the polymer under controlled conditions, such as heating, is phosphoric acid.

In some embodiments of the present invention, the concentration of the acid-releasing polymer in the composition ranges from about 5 percent to 20 percent by weight of the total weight of the composition (% wt).

In some embodiments, the acid-releasing polymer is characterized by an average molecular weight that ranges from 2,000 g/mol to 10,000 g/mol, or from 3,000 g/mol to 8,000 g/mol, from 3,000 g/mol to 5,000 g/mol, from 2,000 g/mol to 7,000 g/mol.

The acid-releasing polymer is selected to be harmless to the inkjet machinery by not being corrosive thereto, therefore the composition comprising the acid-releasing polymer is substantially devoid of a corrosive agent, and is also non-degrading to fabrics until it is heated. The composition comprising the acid-releasing polymer is designed to release an acid upon heating the composition, typically after it has been applied on the fabric. In some embodiments, the composition releases an acid when it is heated to, or when the fabric it is applied on is heated to at least 160° C., at least 170° C., at least 180° C., at least 190° C. or at least 200° C. and higher.

In some embodiments of the present invention, the acid-releasing polymer exhibits an alkyl phosphate group, an alkyl-alkoxy phosphate groups and/or a combination thereof.

The term “alkyl phosphate”, as used herein, refers to a R—OP(═O)(OH)₂ or a R—OP(═O)(OH)O⁻ group, wherein R is an alkyl.

The term “alkyl-alkoxy phosphate”, as used herein, refers to a R—OP(═O)(OH)OR′ or a R—OP(═O)(OR′)O⁻ group, wherein R and R′ are each an alkyl.

As used herein, the term “alkyl” describes an aliphatic hydrocarbon including straight chain and branched chain groups. The alkyl group may exhibit 1 to 20 carbon atoms, and preferably 8-20 carbon atoms. Whenever a numerical range; e.g., “1-20”, is stated herein, it implies that the group, in this case the alkyl group, may contain 1 carbon atom, 2 carbon atoms, 3 carbon atoms, etc., up to and including 20 carbon atoms. The alkyl can be substituted or unsubstituted, and/or branched or unbranched (linear). When substituted, the substituent can be, for example, an alkyl, an alkenyl, an alkynyl, a cycloalkyl, an aryl, a heteroaryl, a halo, a hydroxy, an alkoxy and a hydroxyalkyl as these terms are defined herein. The term “alkyl”, as used herein, also encompasses saturated or unsaturated hydrocarbon, hence this term further encompasses alkenyl and alkynyl.

The term “alkenyl” describes an unsaturated alkyl, as defined herein, having at least two carbon atoms and at least one carbon-carbon double bond. The alkenyl may be branched or unbranched (linear), substituted or unsubstituted by one or more substituents, as described herein.

The term “alkynyl”, as defined herein, is an unsaturated alkyl having at least two carbon atoms and at least one carbon-carbon triple bond. The alkynyl may be branched or unbranched (linear), and/or substituted or unsubstituted by one or more substituents, as described herein.

The terms “alicyclic” and “cycloalkyl”, refer to an all-carbon monocyclic or fused ring (i.e., rings which share an adjacent pair of carbon atoms), branched or unbranched group containing 3 or more carbon atoms where one or more of the rings does not have a completely conjugated pi-electron system, and may further be substituted or unsubstituted. The cycloalkyl can be substituted or unsubstituted by one or more substituents, as described herein.

The term “aryl” describes an all-carbon aromatic monocyclic or fused-ring polycyclic (i.e., rings which share adjacent pairs of carbon atoms) groups having a completely conjugated pi-electron system. The aryl group may be substituted or unsubstituted. Substituted aryl may have one or more substituents as described for alkyl herein.

The term “heteroaryl” describes a monocyclic or fused ring (i.e., rings which share an adjacent pair of atoms) group having in the ring(s) one or more atoms, such as, for example, nitrogen, oxygen and sulfur and, in addition, having a completely conjugated pi-electron system. Representative examples of heteroaryls include, without limitation, furane, imidazole, indole, isoquinoline, oxazole, purine, pyrazole, pyridine, pyrimidine, pyrrole, quinoline, thiazole, thiophene, triazine, triazole and the like. The heteroaryl group may be substituted or unsubstituted as described for alkyl herein.

The term “halo” refers to —F, —Cl, —Br or —I.

The term “hydroxy”, as used herein, refers to an —OH group.

The terms “alkoxy” and “hydroxyalkyl” refer to a —OR group, wherein R is alkyl.

In some embodiments of the present invention, the alkyl in the alkyl phosphate group and/or said alkyl-alkoxy phosphate group of the acid-releasing polymer is a C₈₋₂₀ linear alkyl, or a C₈₋₂₀ linear alkyl, or a C₈₋₁₅ linear alkyl, or a C₈₋₁₀ linear alkyl.

According to some embodiments, the polymeric moiety of the acid-releasing polymer is a polyoxyethylene, or a polyethylene glycol, such that the acid-releasing polymer is a polyoxyethylene alkyl ether phosphate. The acid-releasing polymer may be represented by general Formula I:

wherein:

each of Z₁ and Z₂ is independently H or a moiety represented by general Formula II:

provided that at least one of Z₁ and Z₂ is said moiety;

A⁺ is H⁺ or a metal cation or an ammonium ion;

n is an integer that ranges from 50-200; and

R is a C₈₋₂₀ alkyl.

In some embodiments, the acid-releasing polymer is present in the composition as a free acid, a salt (e.g., sodium salt, ammonium salt, and the like) or a combination thereof in a buffered equilibrium.

In some embodiments, the acid-releasing polymer is present in the composition a mixture of species having one Z₁/Z₂ moiety represented by general Formula II and having two Z₁/Z₂ moieties represented by general Formula II.

The polyoxyethylene alkyl ether phosphate acid-releasing polymer, according to some embodiments of the present invention, is capable of releases phosphoric acid upon heating the composition to at least 160° C., at least 170° C., at least 180° C., at least 190° C. or at least 200° C. and higher.

While the released phosphoric acid can degrade cellulosic fibers, it is harmful to the inkjet machinery parts and environment; thus the composition, prior to heating, is substantially devoid of phosphoric acid at a temperature that ranges from room temperature to inkjet printhead working temperature (20-50° C.; typically 28-34° C. Nonetheless, while still essentially harmless to the printhead and other part of the inkjet machinery, the composition is having a pH that ranges from 2 to 5 at room temperature.

According to some embodiments of the present invention, prior to heating, the digital burnout composition described herein is substantially devoid of sodium dihydrogen phosphate, sulfuric acid and derivatives thereof, sodium hydroxide, sodium hydrogen sulfate and/or aluminum sulfate.

Composition for Annulling or Arresting Burnout of Fabrics:

According to another aspect of embodiments of the present invention, there is provided a burnout-annulling composition that includes a neutralizing agent and a carrier, the neutralizing agent can annul the degradation, corrosion, etching, digestion and/or carbonization of cellulosic or proteinous fibers, which can be effected by a corresponding fiber-selective burnout agent.

As used herein, the term “neutralizing agent” refers to a substance that can substantially neutralize the reactivity of the fiber-selective burnout agent upon contact therebetween. For example, an acid-releasing burnout agent can be neutralized by contacting with a base (e.g., NaOH, EDTA, ammonium hydroxide, various amines, and the like), thereby neutralizing its reactivity towards cellulosic fibers; and a proteolytic enzyme burnout agent can be neutralized by an inhibitor of the enzyme or a protein denaturation agent that degrades the enzyme, thereby neutralizing its reactivity towards proteinous fibers.

Exemplary protein denaturants include, for example, acids (e.g., picric acid, acetic acid, trichloroacetic acid and sulfosalicylic acid), bases (e.g., sodium bicarbonate), solvents (e.g., alcohol and most organic solvents), cross-linking reagents (e.g., EDC, formaldehyde, glutaraldehyde), chaotropic agents (e.g., urea, guanidinium chloride, lithium perchlorate), and disulfide bond reducers (e.g., 2-mercaptoethanol, dithiothreitol, tris(2-carboxyethyl)phosphine). Proteolytic enzymes can also be denatured by desiccation, mechanical agitation, radiation and high temperature.

Digital Burnout Process:

According to some embodiments of an aspect of the present invention, there is provided a process for digital burnout of fabrics, the process is effected by:

providing and placing (mounting; fixing) a fabric in a inkjet printing machine equipped with at least one printhead for inkjet printing a composition for digital burnout of a fabric, essentially as presented herein; and

digitally printing a composition for digital burnout of a fabric on at least one part of the fabric, following a predetermined digital pattern.

According to some embodiments of an aspect of the present invention, there is provided a process for digital cutting of a fabric consisting of degradable fibers, the process is effected by:

providing and placing (mounting; fixing) a fabric in a inkjet printing machine equipped with at least one printhead for inkjet printing a composition for digital burnout of a fabric, essentially as presented herein; and

digitally printing a composition for digital burnout of a fabric on at least one part of the fabric, following a predetermined digital pattern.

wherein the composition for digital burnout of a fabric includes at least one degradable fiber-specific burnout agent.

Thus, digital cutting of a fabric consisting of degradable fibers, such as cellulosic and/or proteinous fibers, is effected by deploying a digital burnout composition which includes cellulosic and/or proteinous-specific fibers. Since no impervious fibers are present in the fabric, the fabric is cut at the areas (pattern) on which the digital burnout composition is printed; for example, to cut a cellulosic fabric along a line, the process includes printing a digital burnout composition comprising a cellulosic fiber burnout agent in a pattern of a line. Fabrics comprising silk and cotton can be cut by using a digital burnout composition that includes a cellulosic fiber burnout agent and a proteinous fiber burnout agent.

The phrase “predetermined digital pattern”, as used herein, refers to a predetermined design, such as linear and/or curved lines, dots, areas and any combination thereof, which is translated into a set computer-edited, compiled, stored, delivered and executed digital commands. The digital commands are carried out by a digital inkjet printing machine that directly places droplets of a liquid composition, such as the composition for digital burnout of a fabric presented herein, on a surface of a substrate (e.g., a fabric), the coverage of which corresponds to the predetermined design.

In some embodiments of the process for digital burnout of fabrics, the digital burnout composition includes a proteinous fiber-selective burnout agent, and the fabric comprises at least some proteinous fibers.

In some embodiments of the process for digital burnout of fabrics, the digital burnout composition includes a cellulosic fiber-selective burnout agent, and the fabric comprises at least some cellulosic fibers.

In some embodiments of the process for digital burnout of fabrics, the fabric includes at least some cellulosic fibers and some synthetic and/or proteinous fibers. The total amount of cellulosic fibers in the fabric may range from 5% to 80% of the total fibers in the fabric.

In some embodiments of the process for digital burnout of fabrics, the fabric consists of cellulosic fibers. In such embodiments, the process for digital burnout of fabrics can be used to cut the fabric according to a predetermined digital pattern, since the fabric is made entirely of fibers that can be degraded by the burnout composition. A process for cutting a fabric by use of a digital burnout composition is demonstrated in the Examples section that follows below.

In order to effect devoré or cutting of the fabric, the process further includes, subsequent to the printing step, heating the printed fabric to at least 160° C. to thereby degrade the composition-sensitive fiber, e.g., cellulosic fibers. In some embodiments, the process further includes, subsequent to the heating step, removing and cleaning residues of the degraded fibers. Cleaning the residues of the degraded fibers is effected by wet or dry cleaning, washing, air blowing, shaking and agitating the fabric, and any method known in the art for removing debris and loose fibers from a fabric.

In some embodiments of an aspect of the present invention, the digital burnout process includes the use of a burnout-annulling composition that includes a neutralizing agent capable of preventing, attenuating and/or arresting the burnout reaction effected by a corresponding burnout agent. The process includes applying to the substrate a burnout-annulling composition on the substrate before, during and/or after applying a digital burnout composition as provided herein, wherein the burnout-annulling composition is applied on areas of the substrate where burnout is required to be prevented, attenuated and/or arrested.

In some embodiments, the burnout-annulling composition is formulated for ejection from inkjet machinery, as defined hereinabove.

According to some embodiments of the present invention, the process may further include printing one or more ink composition comprising a colorant on the fabric. The color printing can be effected on non-burnout areas of the fabric, on burnout areas or in any part of the fabric, regardless of the devoré pattern. Printing on the fabric can be carried out by any printing protocol, method and process, before the fabric is printed with the digital burnout composition, after printing the digital burnout composition, and before or after the fabric is heated. Exemplary color printing methodologies are presented in the background section of the present invent, however any color printing methodology is contemplated within the scope of the present invention.

Digital Burnout Machine and Algorithm:

In some embodiments of an aspect of the present invention, there is provided a digital burnout machine, which is designed to effect burnout of a fabric using inkjet technologies and methodologies.

In some embodiments of the present invention, the digital burnout machine is equipped with at least one printhead that is designated to deploy a composition for digital burnout of a fabric, as described herein, and/or at least one printhead or spray nozzle to deploy a burnout-annulling composition, as described herein.

Suitable printheads useful for deploying the digital burnout composition and/or the burnout-annulling composition, according to some embodiment of the present invention, include, without limitation, Kyocera-KJ4B Series (e.g., KJ4C-0360), SII printek-Seiko (e.g., RC1536), Konica Minolta (e.g., KM1800i), Ricoh (e.g., MH5420/5440; GH2220; and MH2620), Trident (e.g., 256JET-S), XAAR (e.g., 2001+; 1201; and 5601), and Spectra (e.g., SG1024; samba; GMA; PQ 35 pl; and PQR S\M\L).

The machine is driven by a software that follows an algorithm, which is designed to drive the printhead(s) according to a predetermined digital pattern, as described herein.

The machine and algorithm can be designed in and for any configuration known in the inkjet field, including a roll-to-roll configuration, a single station configuration, a matrix configuration and a carousel configuration, as these are known in the art.

In the presently known digital textile printing industry, a designated machine is needed for printed fabric roll cutting, wherein the garment is pretreated, printed, dried and then cut and packaged. According to some embodiments of the present invention, a single integrated system for in-line digital printing and chemical cutting is provided herein. The benefits of using such integrated system include, without limitation, cutting that is carried out digitally using a digital burnout composition as described herein; and use of inkjet technology to accurately carry out integrated printing and chemical cutting.

A chemical cutting formulation in the form of the presently provided digital burnout composition, can be jetted through an inkjet printhead which forms a part of an inkjet printing machine or system. The printhead is be mounted on a printhead carriage. A Drop-On-Demand printhead prints a high resolution line, which allows the digital burnout composition to be placed exactly where the chemical cutting process is needed. The printing and cutting processes occur continuously without interfering or adding an additional stages to the process. The fabric roll stays in one piece and only when it goes through the dryer a fabric burnout reaction starts, leading to separation of the printed pieces for additional cleaning, sewing or finishing processes.

This integrated solution is an important and innovated part in the digital printing field which offers the user to print an individual or a single print and cut it easily without using any additional tools or machines.

A Fabric Having a Burnout Pattern:

In some embodiments of an aspect of the present invention, there is provided a fabric having a burnout pattern formed therein or thereon, effected by using the digital burnout composition presented herein.

In some embodiments of an aspect of the present invention, there is provided a fabric having a burnout pattern formed therein or thereon, prepared by using the digital burnout process presented herein.

In some embodiments of an aspect of the present invention, there is provided a fabric having a burnout pattern formed therein or thereon, formed by using the digital burnout machine presented herein.

The fabric having a digitally-formed burnout pattern can be shaped and fashioned into a garment or any other product comprising a fabric, hence the term “product” is meant to encompass any article of manufacturing comprising a fabric having a digitally-formed burnout pattern therein or thereon, according to embodiments of the present invention.

The product, according to some embodiments of the present invention, is characterized by specific “fingerprints” imparted by the unique composition, process, machine and/or algorithm for digital burnout of fabrics presented in the foregoing.

It is expected that during the life of a patent maturing from this application many relevant compositions, processes, machines and algorithms will be developed and the scope of the terms composition, process, machine and algorithm is intended to include all such new developments a priori.

As used herein the term “about” refers to ±10%.

The terms “comprises”, “comprising”, “includes”, “including”, “having” and their conjugates mean “including but not limited to”.

The term “consisting of” means “including and limited to”.

The term “consisting essentially of” means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the phrases “substantially devoid of” and/or “essentially devoid of” in the context of a certain substance, refer to a composition that is totally devoid of this substance or includes less than about 5, 1, 0.5 or 0.1 percent of the substance by total weight or volume of the composition. Alternatively, the phrases “substantially devoid of” and/or “essentially devoid of” in the context of a process, a method, a property or a characteristic, refer to a process, a composition, a structure or an article that is totally devoid of a certain process/method step, or a certain property or a certain characteristic, or a process/method wherein the certain process/method step is effected at less than about 5, 1, 0.5 or 0.1 percent compared to a given standard process/method, or property or a characteristic characterized by less than about 5, 1, 0.5 or 0.1 percent of the property or characteristic, compared to a given standard.

The word “exemplary” is used herein to mean “serving as an example, instance or illustration”. Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments.

The words “optionally” or “alternatively” are used herein to mean “is provided in some embodiments and not provided in other embodiments”. Any particular embodiment of the invention may include a plurality of “optional” features unless such features conflict.

As used herein, the singular form “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a compound” or “at least one compound” may include a plurality of compounds, including mixtures thereof.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

As used herein the terms “process” and “method” refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the chemical, material, mechanical, computational and digital arts.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Various embodiments and aspects of the present invention as delineated hereinabove and as claimed in the claims section below find experimental support in the following examples.

EXAMPLES

Reference is now made to the following examples, which together with the above descriptions illustrate some embodiments of the invention in a non-limiting fashion.

Example 1 Digital-Chemical Cutting of a Cellulosic Fabric

A proof of concept of some embodiments of the present invention was carried out by digitally executed chemical cutting of a cellulosic fabric using a cellulosic fiber-specific burnout agent in the form of an acid-releasing polymer.

For an exemplary cellulosic fiber-specific burnout agent, according to some embodiments of the present invention, the inventors have used a commercially available dispersant, known as SOLPLUS® D540, which is a polyoxyethylene alkyl ether phosphate, provided by the Lubrizol Corporation, USA.

Exemplary compositions for digital burnout of a cellulosic fabric were formulated as follows:

Cellulosic fiber burnout agent (SOLPLUS ® D540)    2-10% Surfactant (DYNOL ® 360)  0.1-0.5% Humectant/wetting agent (Propylene glycol; PG) 50% Antibacterial agent 0.05-0.2% Carrier (Deionized water) to QS pH    2-4

The mechanical properties of the compositions for digital burnout of a cellulosic fabric included:

Maximal particle size of less than 1 microns;

a dynamic viscosity 12-20 centipoise at shear of 4000 rpm;

a Brookfield viscosity of 14 centipoises at 30° C.;

a surface tension of 30-35 mN/m; and

an electrical resistance of 1000 ohm per centimeter.

The printing machine Kornit Avalanche Hexa was used to print a straight line of droplets having a volume of 85 picoliter along a 100% cotton fabric, equipped with a Fujifilm Dimatix Polaris 85 Pico liter (PQ85) printhead.

The fabric was then heated in a curing oven set to 160-200° C.

FIG. 1 presents a photograph of the cotton fabric cut using the digital burnout composition and process essentially as described herein.

As can be seen in FIG. 1, the 100% cotton fabric was cut along a straight line, the area of which was contacted with the cellulosic fiber-selective burnout agent, according to some embodiments of the present invention.

The same composition and process were employed on a polyester fabric, and the fabric was not affected thereby, namely the cellulosic fiber-selective burnout agent used to cut a 100% cotton fabric left no visible marks on the 100% polyester fabric after the same treatment.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting. 

What is claimed is:
 1. A composition for digital burnout of a fabric, comprising an acid-releasing polymer and a carrier, being formulated for ejection from inkjet machinery.
 2. The composition of claim 1, being formulated for soaking into the fabric to thereby reach a plurality of fibers constituting the fabric.
 3. The composition of claim 1, wherein a dynamic viscosity and/or a Brookfield viscosity at printing temperature and/or a surface tension and/or an electrical resistance of the composition is suitable for inkjet.
 4. The composition of claim 1, being characterized by at least one of: a maximal particle size of less than 1 micron; a dynamic viscosity at shear that ranges from 2 to 25 centipoise; a Brookfield viscosity less than 25 centipoises at printing temperature; a surface tension that ranges from 24 to 35 mN/m; and an electrical resistance of 50 to 2000 ohm per centimeter.
 5. The composition of claim 1, wherein a concentration of said acid-releasing polymer ranges from 5% wt to 20% wt.
 6. The composition of claim 1, wherein said acid-releasing polymer comprises an alkyl phosphate group, an alkyl-alkoxy phosphate groups and a combination thereof.
 7. The composition of claim 1, wherein said acid-releasing polymer is a polyoxyethylene alkyl ether phosphate.
 8. The composition of claim 1, wherein said acid-releasing polymer is represented by general Formula I:

wherein: each of Z₁ and Z₂ is independently H or a moiety represented by general Formula II:

provided that at least one of Z₁ and Z₂ is said moiety; A⁺ is H⁺ or a metal cation or an ammonium ion; n is an integer that ranges from 50-200; and R is a C₈₋₂₀ alkyl.
 9. The composition of claim 1, wherein said acid-releasing polymer releases phosphoric acid upon heating the composition to 160° C. or higher.
 10. The composition of claim 9, substantially devoid of phosphoric acid at a temperature that ranges from room temperature to inkjet printhead working temperature.
 11. The composition of claim 1, having a pH that ranges from 2 to 5 at room temperature.
 12. A process for digital burnout of fabrics, the process comprising: providing a fabric; and printing a digital burnout composition on said fabric in a predetermined digital pattern, wherein said digital burnout composition comprises an acid-releasing polymer and a carrier, said fabric comprises a cellulosic fiber.
 13. The process of claim 12, wherein said digital burnout composition comprises an acid-releasing polymer and a carrier, being formulated for ejection from inkjet machinery.
 14. The process of claim 12, wherein said fabric comprises a cellulosic fiber and a synthetic and/or proteinous fiber.
 15. The process of claim 14, wherein said fabric comprises at least 20% cellulosic fiber.
 16. The process of claim 12, further comprising, subsequent to said printing, heating said fabric to at least 160° C. to thereby degrade said cellulosic fiber.
 17. A process for digital cutting of a fabric consisting of degradable fibers, the process comprising: placing the fabric in a inkjet printing machine equipped with at least one inkjet printhead; and digitally printing a composition for digital burnout of a fabric on at least a part of the fabric, following a predetermined digital pattern; wherein said composition comprises at least one degradable fiber-specific burnout agent for each degradable fiber in the fabric.
 18. The process of claim 17, wherein said digital burnout composition comprises an acid-releasing polymer and a carrier, being formulated for ejection from inkjet machinery.
 19. The process of claim 17, further comprising, subsequent to said printing, heating said fabric to at least 160° C. to thereby degrade the degradable fibers.
 20. The process of claim 19, further comprising, subsequent to said heating, removing residues of the degraded degradable fibers. 